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1
ISSN: 2277-3754
ISO 9001:2008 Certified
International Journal of Engineering and Innovative Technology (IJEIT)
Volume 7, Issue 2, August 2017
copper foams by using polymeric materials for working electrode, platinum as a counter electrode (1 cm2)
electrochemical analysis application and to understand the and silver / silver chloride (Ag/AgCl) (+220 mV vs. normal
effect of epoxy resin on performance copper foam electrode hydrogen electrode as a reference electrode (HANNA
in an electrochemical cell, corrosion rate and mechanical Instruments, Italy). The electrolyte is 0.05 M KNO3, and 0.1
behavior of copper foam products. M Zn (NO3) 2y, and the analytical grade reagents worked at
room temperature. The working and counter electrodes were
II. MATERIALS & METHODOLOGY mounted parallel to each other at a distance of 0.5 cm a part,
In this study the copper powder fabricated by a water without stirring. All substrates were cleaned by an ultrasonic
atomization method with particle size 150 µm and 99% purity bath with deionized water followed by rinsing in an ethanol
was mixed with an epoxy resin by three percent 12.5, 25 and bath. Copper substrate samples were etched for 15 sec. With
50 wt. % in the presence of 1wt.% foaming agent . A dilute hydrochloric acid to eliminate the oxide layer. Prior to
dispersing agent of 1wt.% was also added for improving the the film deposition, the copper substrate was polished with
wettability and dispersity of Cu particles with the polymeric emery paper, followed by an etching process in dilute
material. They are mixed with each others at room hydrochloric acid for 30 s and rinsing in distilled water. This
temperature with rotation speed of 50 RPM, then sintered at preparation method provides chemically clean and smooth
two different temperatures 600 & 800oC under argon surface, which is important for the cyclic voltammetry
studies. Cyclic voltammetry curves were measured by
atmosphere to prevent the oxidation process. The density was
sweeping from 1000 to -2000 mV vs and Ag/AgCl electrode
estimated by Archimedes principle, in which the actual
at a selected potential was sweeped by a rate of 10 mV s-1.
density of the prepared samples was determined according to
The voltammetric response was obtained from a
ASTM D1217 standard, using water as a floating liquid high-performance 20 V/1A potentiostate/galvanostate, Volta
according to MPIF standard 42, 1998. The sintered specimens Lab 21 PGP 201 model, coupled to a computer to record
were weighed in air and in distilled water after its capsulation current and potentials. The resulting deposited ZnO film on a
with paraffin wax to prevent entering of water in the pores, copper electrode was rinsed thoroughly with water, ethyl
then their densities (D) were calculated according to the alcohol then dried under vacuum in a desiccator for one hour.
following equation:-
D = Wa / (Wa - Ww) III. RESULTS AND DISCUSSIONS
Where, Wa and Ww are the masses of the sample in air and A. Densification and Porosity Measurements
water respectively. The relative density of the composite is The relative porosity of Cu-foam samples sintered at 600
the ratio of the measured sintered density (actual density) to and 800 ⁰C are given in figure (1). There are two phenomena
the theoretical one. The degree of porosity of the sintered the higher porosity percent of samples sintered at 800 ⁰C than
compacts was calculated according to the following those sintered at 600 ⁰C, which may be due to the suitable
equation:- sintering temperature, for complete decomposition of the
Porosity% = (Dth-Do)/Dth%
polymeric material with a foaming agent that gives a large
Where, Dth is the theoretical density of the sintered sample
number of pores. The second phenomena are the higher
and Do is the actual density. The phase constituent of the
porosity percent of sample containing 50 wt. % epoxy resin,
sintered specimens was achieved by x-ray diffraction analysis
using x-ray diffractometer model x, pert PRO which may be attributed to the suitable epoxy resin percent
PANALYTICAL with Cu kα radiation (λ=0. 15406 nm). The with 1 wt%. Foaming agent at 800 oC sintering temperature.
sintered samples were ground successively with 600, 800, While 1 wt. The % foaming agent is not sufficient for 12.5 and
1000, 1200, 2000 and 3000 grit SiC papers. Then, the 50 wt. % epoxy resin. So, 25 wt% epoxy resin with 1 wt%.
specimens were polished with 3 micrometer alumina paste Foaming agent added for copper powder and sintered at 800
using a machine model "Buhlertm". The microstructure of the OC is the most suitable parameters that give the highest.
polished samples was investigated by Field emission scanning
electron microscope (FE-SEM), model (FE-SEM;
QUANTAFEG250, Holland) equipped with energy
dispersive X-ray (EDX) spectrometers, and secondary
electron (SE) and backscattered electron (BSE) detectors for
the determination of particle size, morphology and chemical
composition. Compression strength testing of the
investigated samples was also measured using uniaxial
SHIMADZU universal testing machine UH-F500KN. The
area of the specimen is (65.86 mm2) and the applied
cross-head speed is 2mm/min. The test was conducted at
room temperature. Copper foam can be used as an electrode in
electrochemical cells, this is achieved by immersing the Cu
foam in an electrolyte in which a conventional three-electrode Fig. (1) The density and porosity of the Cu foam with 12.5, 25
cell was used with different copper sheets (1 cm2) as a and 50 wt. % epoxy resin sintered at 600 and 800 ⁰C.
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ISSN: 2277-3754
ISO 9001:2008 Certified
International Journal of Engineering and Innovative Technology (IJEIT)
Volume 7, Issue 2, August 2017
B. XRD Measurement 1. Optical Microscopic Studies
The phase structure of copper foam specimens with 12.5, Figures (5 and 6) show the optical micrographs of 12.5, 25
25 and 50 wt. % epoxy resin are estimated by X-ray and 50 wt.% epoxy resin samples sintered at 600 oC and 800
diffraction. Figure (2) represents the XRD pattern which oC respectively . The results indicated the appearance of two
indicated that only peaks corresponding to copper metal were types of pores, open pores and closed nearly rounded pores.
observed in all samples sintered at both 600& 800 Oz. This Samples sintered at 800 oC have connected and irregular
may be due to the complete dissociation of the epoxy resin to pores, this may be due to the higher sintering temperature,
carbon dioxide gas and water vapor during the sintering which causes the complete dissociation of the epoxy resin and
process. foaming agent, also give the chance for connection of the
pores with each others. Also cell wall is dense and only micro
pores or voids can be seen and the pores are not uniaxial. The
pores are distributed in a nearly homogeneous manner all over
the copper matrix, in which copper matrix is well sintered
around the pores while samples sintered at 600 oC has a
separate and connected pore, as the temperature is not
sufficient for complete sinterability and connection of pores
[11].
C. Photographic Investigations
Figure (3) and (4) show the photo images of copper foam
with 12.5, 25 and 50 wt.% epoxy resin samples sintered at 600
& 800 0C respectively. The samples are in the shape of a
rectangle or cubic form. The porous structure is clear in all FIG (5) METALLOGRAPHIC CROSS SECTION OF (A)12.5 WT.% , (B)
25WT.%, (C) 50 WT.% EPOXY RESIN COPPER FOAM SAMPLES
samples and distributed in a homogeneous manner.
SINTERED AT 600 0C.
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ISSN: 2277-3754
ISO 9001:2008 Certified
International Journal of Engineering and Innovative Technology (IJEIT)
Volume 7, Issue 2, August 2017
homogenization between Cu powder, epoxy resin and the according to the following scheme [12]
foaming agent during the mixing process that play an
important role in this process, as these pores are attributed to NO3- + H2O + 2 e- = NO2- + 2 OH- (E0 = - 0.24 V vs. SCE) (1)
Zn2++2OH-=Zn(OH)2(S) (2)
the decomposition and evaporation of polymeric material
Zn (OH) 2 (S) = ZnO + H2O (3)
during the sintering process.
The overall expression of the reaction is:
Zn2+ + NO3- + 2 e- = ZnO + NO2- (E0 = - 0.246 V vs. SCE) (4)
The cathodic electrode position of ZnO thin film from nitrate
solution is thought to proceed via the reduction of nitrate ions
according to equation (1). The as-generated hydroxide ions
would react with Zn2+ ions to form Zn(OH)2 according to
equation (2). Subsequently, Zn(OH)2 is spontaneously
dehydrated into ZnO equation )3). During the electrode
position of ZnO films, nitrate ions are used as oxygen
precursor.
Fig (7) Scanning electron micrographs of 25 wt. % epoxy 1 Copper Foam Samples Sintered at 600 oC
resin copper foam samples sintered 800 0C at (a) 70 X (b) 100 X Figure (9) shows four typical cyclic voltammograms
(c) 250 X . recorded with four different copper electrodes in a bath
E. Compression Strength containing 0.05 M Zn (NO3)2 + 0.05 M KNO3. Curve
The compression strength of a foaming material depends (standard) displays the cyclic voltammogram recorded in the
greatly on the density; also pore distribution, size and shape. deposition solution of ZnO on solid, non porous copper
Figure (8) shows the experimental stress–strain curves for substrate which is prepared from water atomized copper
copper foam with 12.5, 25 and 50 wt.% epoxy resin samples powder that compacted under 700 MPa pressure, then
sintered at 800 0C. All curves display one behavior for all sintered in a vacuum furnace at 900 oC for 1 hour. This
samples illustrated as follows; in this first step at the sample was used as a reference sample for the comparison
beginning of the load the specimens deformed elastically and with the three copper foam samples, in this curve, ZnO begins
bending occurs only, in this section the pore remained to deposited at potential -100 mV (Ag/AgCl), and cathode
unharmed. The second step copper foam 50 wt. % epoxy potential of -1.2 V vs. Ag/AgCl a steep increase of the
sample has the lowest compressive strength value due to the cathodic current takes place up to 13 mA cm-2 which
high porosity percent created by the epoxy and foaming corresponding to nitrate ions reduction and hydrogen gas
materials percent in which the pore are considered a weak evolution but observed anodic current is 20 mA cm-2
point for crack initiation and propagation [11]. associated with anode potential 20 mV and is likely due to
oxygen evolution [12, 13]. The rate of ZnO electrode position
reaction and rate of anodic reaction are directly proportional
to the recorded deposition current value in the
voltammogram.
Curve (S1) which represents the cyclic voltamogram of Cu
– 12.5 wt% epoxy sample. It displays the cyclic
voltammogram recorded in the deposition solution of ZnO on
porous copper substrate sintered at 600 0C. ZnO deposition
begins at cathodic deposition potential -300 mV higher than
that of standard non porous Cu. Also at the cathode potential
of -1.5 V a week increase of the cathodic current takes place
up to 5 mA cm-2 that corresponding to hydrogen gas
evolution [12]. In the anodic reverse direction, the observed
oxygen evolution current of standard non porous Cu is 2 mA
Fig. (8) Compressive stress–strain curves for Cu foam 12.5, 25,
cm-2 and started at anodic potential 500 V [13]. Also the
50 wt.% epoxy resin sintered at 800 ⁰C.
deposition potential is higher than that of standard non porous
F. Copper Foam as an Electrode for ZnO Film Formation
Cu by -300 mV and the deposition current is lower by 8
Porous copper foam can be used, as an electrode for
mAcm-2. In additions, the anodic potential is higher by 480
electrochemical deposition of metals, by immersing in an
mV and the anodic current is lower than that of curve 1
electrolytic solution of an electrochemical cell. In this work
(standard non porous Cu) by 18 mAcm-2. Similar behavior
Cu-foam electrode was used in cyclic Voltammetry of ZnO
was observed with the fourth curve (S3), which displays the
film deposition by immersing in Zinc nitrate solution, based
cyclic voltammogram of ZnO on porous copper substrate.
on the reduction of nitrate at the copper foam electrode,
The deposition potential of curve S3 is higher than that of
raising the local pH and causing precipitation of the
curve by -400 mV while the deposition current is lower than
hydroxide phase and subsequent dehydration to the oxide,
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ISSN: 2277-3754
ISO 9001:2008 Certified
International Journal of Engineering and Innovative Technology (IJEIT)
Volume 7, Issue 2, August 2017
that of curve 1 by 11 mAcm-2. Also the anodic potential of S2 curve displays the cyclic voltammogram for the
curve S3 is higher than that of curve 1 by 580 mV and the deposition solution of ZnO on porous copper substrate
anodic current is lower by 19 mAcm-2. contains 25 wt.% epoxy resin. In this curve, ZnO deposition
begins at cathodic deposition potential -300 mV higher than
that of standard non porous Cu. Also at the cathode potential
of -500 mV, in which a small increase of the cathodic current
takes place up to 7 mA cm-2 which corresponding to
hydrogen gas evolution [12]. In the anodic reverse direction,
the observed oxygen evolution current is 3 mA cm-2 and
started at anodic potential of 500 mV [13].
The deposition potential of curve S2 is higher than that of
curve 1 by - 200 mV and the deposition current is lower by 6
mAcm-2, while the anodic potential is higher by 500 mV and
the anodic current is lower by 17 mAcm-2. All these resulte
indicated that 25 wt.% epoxy resin porous copper sample
Curve (S1) is the best in its electrochemical deposition
behavior.
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ISSN: 2277-3754
ISO 9001:2008 Certified
International Journal of Engineering and Innovative Technology (IJEIT)
Volume 7, Issue 2, August 2017
the corrosion [14]. While, as the sample becomes more dense foam with 12.5 % wt. epoxy resin in nitrate bath was about
this resists the corrosion. 2.535 mm/Y while the corrosion current was 0.21 mA cm-2.
Porous sample number 1 sintered at 800 0C is the nearest and
best porous sample in its electrochemical corrosion behavior
with respect to other samples. While, sample number 2
showed the worst one.
Copper foams are characterized by excellent ductility as
well as good thermal and electrical conductivities this gives it
the facilities to use as, pours electrodes, a catalectic substrate
for chemical reactions and filtrations applications also the
pores structure is considered a mean factor for a uniform
distribution of pours which plays a big role in all the above
applications.
IV. CONCLUSION
In the present work, Copper foam are fabricated using
copper powder with Polymeric materials by powder
technology technique to be used as an electrode in
Fig. (11) Corrosion behavior of copper samples prepared at
600 0C. electrochemical cell analysis, have been prepared in three
Figure (12) represents the corrosion rate of copper foam electrodes from mixed with 12.5, 25 and 50 wt. % epoxy resin
samples prepared at 800 0C in the same a bath containing 0.1 with copper powder, Cu foam specimens were divided based
M ZnNO3 and 0.05 M KNO3 . It was about 1.062 mm/Y on the sintering temperature at 600 and 800 oC. Based on the
while the corrosion current was 0.0908 mA cm-2. S1 and S3 mechanical, physical and performance of electrode in
samples showed a higher corrosion rate of 1040 and 932 electrochemical cell of the investigated electrodes specimens,
mm/Y with respect to the non porous sample, also a higher the following remarks can be highlighted:
corrosion current of about 88.92 and 79 mm/Y respectively. • After Cu foam sintered have been complete dissociation
For S2 sample the corrosion rate was about 13.68 mm/Y of the epoxy resin to carbon dioxide gas and water vapor
while the corrosion current was 1.14 mA cm-2. and homogeneous distribution of irregular shape pores all
The results showed that S2 sample sintered at 800 0C is the over copper matrix.
nearest on to the non porous sample in its electrochemical
• Increase addition of epoxy resin from 12.5 to 50 wt. %
corrosion behavior. While, S1 sample is the worst one.
and sintering temperature from 600 to 800 leads to a relative
porosity increase.